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Start-Up, Operation, and Maintenance InstructionsSAFETY
CONSIDERATIONS
Centrifugal liquid chillers are designed to providesafe and
reliable service when operated within designspecifications. When
operating this equipment, use goodjudgment and safety precautions
to avoid damage toequipment and property or injury to personnel.Be
sure you understand and follow the procedures and
safety precautions contained in the chiller instructionsas well
as those listed in this guide.
DO NOT VENT refrigerant relief valves within a building.
Outletfrom rupture disc or relief valve must be vented outdoors
inaccordance with the latest edition of ANSI/ASHRAE 15(American
National Standards Institute/American Society of Heat-ing,
Refrigeration, and Air Conditioning Engineers). The accumu-lation
of refrigerant in an enclosed space can displace oxygen andcause
asphyxiation.PROVIDE adequate ventilation in accordance with
ANSI/ASHRAE15, especially for enclosed and low overhead spaces.
Inhalationof high concentrations of vapor is harmful and may cause
heartirregularities, unconsciousness, or death. Misuse can be
fatal.Vapor is heavier than air and reduces the amount of oxygen
avail-able for breathing. Product causes eye and skin irritation.
Decom-position products are hazardous.DO NOT USE OXYGEN to purge
lines or to pressurize a chillerfor any purpose. Oxygen gas reacts
violently with oil, grease, andother common substances.NEVER EXCEED
specified test pressures, VERIFY the allowabletest pressure by
checking the instruction literature and the designpressures on the
equipment nameplate.DO NOT USE air for leak testing. Use only
refrigerant or drynitrogen.DO NOT VALVE OFF any safety device.BE
SURE that all pressure relief devices are properly installed
andfunctioning before operating any chiller.
DO NOT WELD OR FLAMECUT any refrigerant line or vesseluntil all
refrigerant (liquid and vapor) has been removed from chiller.Traces
of vapor should be displaced with dry air or nitrogen andthe work
area should be well ventilated. Refrigerant in contact withan open
flame produces toxic gases.DO NOT USE eyebolts or eyebolt holes to
rig chiller sections orthe entire assembly.DO NOT work on
high-voltage equipment unless you are a quali-fied electrician.DO
NOTWORKON electrical components, including control pan-els,
switches, starters, or oil heater until you are sure ALL POWERIS
OFF and no residual voltage can leak from capacitors or solid-state
components.LOCKOPENANDTAGelectrical circuits during servicing.
IFWORKIS INTERRUPTED, confirm that all circuits are deenergized
be-fore resuming work.AVOID SPILLING liquid refrigerant on skin or
getting it into theeyes. USE SAFETY GOGGLES. Wash any spills from
the skinwith soap and water. If liquid refrigerant enters the eyes,
IMME-DIATELY FLUSH EYES with water and consult a physician.NEVER
APPLY an open flame or live steam to a refrigerantcylinder.
Dangerous over pressure can result. When it is necessaryto heat
refrigerant, use only warm (110 F [43 C]) water.
DO NOT REUSE disposable (nonreturnable) cylinders orattempt to
refill them. It is DANGEROUS AND ILLEGAL. Whencylinder is emptied,
evacuate remaining gas pressure, loosenthe collar and unscrew and
discard the valve stem. DO NOTINCINERATE.CHECK THE REFRIGERANT TYPE
before adding refrigerant tothe chiller. The introduction of the
wrong refrigerant can cause dam-age or malfunction to this
chiller.Operation of this equipment with refrigerants other than
those
cited herein should comply with ANSI/ASHRAE-15 (latest
edi-tion). Contact Carrier for further information on use of this
chillerwith other refrigerants.DONOTATTEMPTTOREMOVEfittings,
covers, etc., while chilleris under pressure or while chiller is
running. Be sure pressure is at0 psig (0 kPa) before breaking any
refrigerant connection.CAREFULLY INSPECT all relief devices,
rupture discs, and otherrelief devices AT LEAST ONCE AYEAR. If
chiller operates in acorrosive atmosphere, inspect the devices at
more frequentintervals.DO NOTATTEMPT TO REPAIR OR RECONDITION any
reliefdevice when corrosion or build-up of foreign material (rust,
dirt,scale, etc.) is found within the valve body or mechanism.
Replacethe device.DO NOT install relief devices in series or
backwards.USE CARE when working near or in line with a compressed
spring.Sudden release of the spring can cause it and objects in its
path toact as projectiles.
DO NOT STEP on refrigerant lines. Broken lines can whip aboutand
release refrigerant, causing personal injury.DO NOT climb over a
chiller. Use platform, catwalk, or staging.Follow safe practices
when using ladders.USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to
lift ormove inspection covers or other heavy components. Even if
com-ponents are light, use mechanical equipment when there is a
risk ofslipping or losing your balance.BE AWARE that certain
automatic start arrangements CAN EN-GAGE THE STARTER, TOWER FAN, OR
PUMPS. Open thedisconnect ahead of the starter, tower fans, or
pumps.USE only repair or replacement parts that meet the code
require-ments of the original equipment.DONOTVENTORDRAINwaterboxes
containing industrial brines,liquid, gases, or semisolids without
the permission of your processcontrol group.DO NOT LOOSEN waterbox
cover bolts until the waterbox hasbeen completely
drained.DOUBLE-CHECK that coupling nut wrenches, dial indicators,
orother items have been removed before rotating any shafts.DO NOT
LOOSEN a packing gland nut before checking that thenut has a
positive thread engagement.PERIODICALLY INSPECT all valves,
fittings, and piping for cor-rosion, rust, leaks, or damage.PROVIDE
A DRAIN connection in the vent line near each pres-sure relief
device to prevent a build-up of condensate or rainwater.
19XLHermetic Centrifugal Liquid Chillers
50/60 HzWith HCFC-22 and HFC-134a
Manufacturer reserves the right to discontinue, or change at any
time, specifications or designs without notice and without
incurring obligations.Book 2Tab 5a
PC 211 Catalog No. 531-971 Printed in U.S.A. Form 19XL-4SS Pg 1
7-96 Replaces: 19XL-3SS
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CONTENTSPage
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . .
1INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4ABBREVIATIONS AND EXPLANATIONS . . . . . . . 4CHILLER
FAMILIARIZATION . . . . . . . . . . . . . . . . . . 5Chiller
Information Plate . . . . . . . . . . . . . . . . . . . . . .
5System Components . . . . . . . . . . . . . . . . . . . . . . . .
. 5Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 5Condenser . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 5Motor-Compressor . . . . . . . .
. . . . . . . . . . . . . . . . . . . 5Control Center . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 5Factory-Mounted
Starter (Optional) . . . . . . . . . . . . 5Storage Vessel
(Optional) . . . . . . . . . . . . . . . . . . . . . 5REFRIGERATION
CYCLE . . . . . . . . . . . . . . . . . . . . . 5MOTOR/OIL
REFRIGERATIONCOOLING CYCLE . . . . . . . . . . . . . . . . . . . .
. . . . . . . 5-8LUBRICATION CYCLE . . . . . . . . . . . . . . . .
. . . . . . . 8,9Summary . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 8Details . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 8Oil Reclaim System
. . . . . . . . . . . . . . . . . . . . . . . . . . 9 DURING NORMAL
CHILLER OPERATION DURING LIGHT LOAD CONDITIONSSTARTING EQUIPMENT .
. . . . . . . . . . . . . . . . . . . 10,11Unit Mounted Solid-State
Starter(Optional) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 10Unit Mounted Wye-Delta Starter(Optional) . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11-39Definitions . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 11 ANALOG SIGNAL DIGITAL SIGNAL VOLATILE
MEMORYGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 11PIC System Components . . . . . . . . . . . .
. . . . . . . . 11 PROCESSOR MODULE (PSIO) STARTER MANAGEMENT
MODULE (SMM) LOCAL INTERFACE DEVICE (LID) 6-PACK RELAY BOARD
8-INPUT MODULES OIL HEATER CONTACTOR (1C) OIL PUMP CONTACTOR (2C)
HOT GAS BYPASS CONTACTOR RELAY (3C)(Optional)
CONTROL TRANSFORMERS (T1-T4) CONTROL AND OIL HEATER
VOLTAGESELECTOR (S1)
LID Operation and Menus . . . . . . . . . . . . . . . . . . . 14
GENERAL ALARMS AND ALERTS MENU STRUCTURE TO VIEW POINT STATUS
OVERRIDE OPERATIONS TIME SCHEDULE OPERATION TO VIEW AND CHANGE SET
POINTS SERVICE OPERATIONPIC System Functions . . . . . . . . . . .
. . . . . . . . . . . . 28 CAPACITY CONTROL ENTERING CHILLED WATER
CONTROL DEADBAND PROPORTIONAL BANDS AND GAIN DEMAND LIMITING
CHILLER TIMERS OCCUPANCY SCHEDULESafety Controls . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 29 SHUNT TRIPDefault Screen
Freeze . . . . . . . . . . . . . . . . . . . . . . . 29
PageMotor Cooling Control . . . . . . . . . . . . . . . . . . .
. . . . 29Ramp Loading Control . . . . . . . . . . . . . . . . . .
. . . . 31Capacity Override . . . . . . . . . . . . . . . . . . . .
. . . . . . . 31High Discharge Temperature Control . . . . . . . .
. 32Oil Sump Temperature Control . . . . . . . . . . . . . . . 32
PSIO SOFTWARE VERSIONS 08 AND LOWER PSIO SOFTWARE VERSIONS 09 AND
HIGHEROil Cooler . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 32Remote Start/Stop Controls . . . . . . . . . .
. . . . . . . . 32Spare Safety Inputs . . . . . . . . . . . . . . .
. . . . . . . . . . 32 SPARE ALARM CONTACTSCondenser Pump Control .
. . . . . . . . . . . . . . . . . . . 32Condenser Freeze Protection
. . . . . . . . . . . . . . . . 32Tower Fan Relay . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 33Auto. Restart After Power
Failure . . . . . . . . . . . . 33Water/Brine Reset . . . . . . . .
. . . . . . . . . . . . . . . . . . . 33 RESET TYPE 1 RESET TYPE 2
RESET TYPE 3Demand Limit Control, Option(Requires Optional 8-Input
Module) . . . . . . . . . . 33Surge Prevention Algorithm . . . . .
. . . . . . . . . . . . 33Surge Protection . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 34Lead/Lag Control . . . . . . . .
. . . . . . . . . . . . . . . . . . . 34 COMMON POINT SENSOR
INSTALLATION CHILLER COMMUNICATION WIRING LEAD/LAG OPERATION
FAULTED CHILLER OPERATION LOAD BALANCING AUTO. RESTART AFTER POWER
FAILUREIce Build Control . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 36 ICE BUILD INITIATION START-UP/RECYCLE OPERATION
TEMPERATURE CONTROL DURING ICEBUILD
TERMINATION OF ICE BUILD RETURN TO NON-ICE BUILD
OPERATIONSAttach to Network Device Control . . . . . . . . . . . .
37 CHANGING REFRIGERANT TYPES ATTACHING TO OTHER CCN MODULESService
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
TO LOG ON TO LOG OFF HOLIDAY
SCHEDULINGSTART-UP/SHUTDOWN/RECYCLESEQUENCE . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 39-41Local Start-Up . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . 39Shutdown
Sequence . . . . . . . . . . . . . . . . . . . . . . . .
40Automatic Soft-Stop Amps Threshold(PSIO Software Version 09 and
Higher) . . . . . . 40Chilled Water Recycle Mode . . . . . . . . .
. . . . . . . . 40Safety Shutdown . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 41BEFORE INITIAL START-UP . . . . . . . . . .
. . . . . . 41-54Job Data Required . . . . . . . . . . . . . . . .
. . . . . . . . . . 41Equipment Required . . . . . . . . . . . . .
. . . . . . . . . . . 41Using the Optional Storage Tankand Pumpout
System . . . . . . . . . . . . . . . . . . . . . . . 41Remove
Shipping Packaging . . . . . . . . . . . . . . . . 41Open Oil
Circuit Valves . . . . . . . . . . . . . . . . . . . . . .
41Tighten All Gasketed Joints andGuide Vane Shaft Packing . . . . .
. . . . . . . . . . . . . 41Check Chiller Tightness . . . . . . . .
. . . . . . . . . . . . . 41Refrigerant Tracer . . . . . . . . . .
. . . . . . . . . . . . . . . . . 41Leak Test Chiller . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 41Standing Vacuum Test .
. . . . . . . . . . . . . . . . . . . . . 43Chiller Dehydration . .
. . . . . . . . . . . . . . . . . . . . . . . 47Inspect Water
Piping . . . . . . . . . . . . . . . . . . . . . . . . 47
2
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CONTENTS (cont)Page
Check Optional Pumpout CompressorWater Piping . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 47Check Relief Devices
. . . . . . . . . . . . . . . . . . . . . . . . 47Inspect Wiring .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Carrier
Comfort Network Interface . . . . . . . . . . . 48Check Starter . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
MECHANICAL-TYPE STARTERS BENSHAW, INC. SOLID-STATE STARTEROil
Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 50Power Up the Controls andCheck the Oil Heater . . . . . .
. . . . . . . . . . . . . . . . . . 50 SOFTWARE VERSIONSet Up
Chiller Control Configuration . . . . . . . . . 50Input the Design
Set Points . . . . . . . . . . . . . . . . . . 50Input the Local
Occupied Schedule(OCCPC01S) . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 50Selecting Refrigerant Type . . . . . . . .
. . . . . . . . . . . 50 TO CONFIRM REFRIGERANT TYPE TO CHANGE
REFRIGERANT TYPEInput Service Configurations . . . . . . . . . . .
. . . . . 50 PASSWORD INPUT TIME AND DATE CHANGE LID
CONFIGURATIONIF NECESSARY
MODIFY CONTROLLER IDENTIFICATIONIF NECESSARY
INPUT EQUIPMENT SERVICE PARAMETERSIF NECESSARY
MODIFY EQUIPMENT CONFIGURATIONIF NECESSARY
CHECK VOLTAGE SUPPLY PERFORM AN AUTOMATED CONTROL TESTCheck
Optional Pumpout SystemControls and Compressor . . . . . . . . . .
. . . . . . . . . 52High Altitude Locations . . . . . . . . . . . .
. . . . . . . . . 53Charge Refrigerant Into Chiller . . . . . . . .
. . . . . . . 53 19XL CHILLER EQUALIZATION WITHOUTPUMPOUT UNIT
19XL CHILLER EQUALIZATION WITHPUMPOUT UNIT
TRIMMING REFRIGERANT CHARGEINITIAL START-UP . . . . . . . . . .
. . . . . . . . . . . . . . . 55,56Preparation . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . 55Manual Operation of
the Guide Vanes . . . . . . . . 55Dry Run to Test Start-Up Sequence
. . . . . . . . . . 55Check Rotation . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 55 IF ROTATION IS PROPER IF THE MOTOR
ROTATION IS NOTCLOCKWISE
NOTES ON SOLID-STATE STARTERS(Benshaw, Inc.)
Check Oil Pressure and Compressor Stop . . . . 56Calibrate Motor
Current . . . . . . . . . . . . . . . . . . . . . 56To Prevent
Accidental Start-Up . . . . . . . . . . . . . . 56Check Chiller
Operating Condition . . . . . . . . . . . 56Instruct the Customer
Operator . . . . . . . . . . . . . . 56 COOLER-CONDENSER OPTIONAL
STORAGE TANK ANDPUMPOUT SYSTEM
MOTOR COMPRESSOR ASSEMBLY MOTOR COMPRESSOR LUBRICATION SYSTEM
CONTROL SYSTEM AUXILIARY EQUIPMENT DESCRIBE CHILLER CYCLES REVIEW
MAINTENANCE SAFETY DEVICES AND PROCEDURES CHECK OPERATOR KNOWLEDGE
REVIEW THE START-UP, OPERATION,AND MAINTENANCE MANUAL
PageOPERATING INSTRUCTIONS . . . . . . . . . . . . . . .
56-58Operator Duties . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 56Prepare the Chiller for Start-Up . . . . . . . . . .
. . . . 56To Start the Chiller . . . . . . . . . . . . . . . . . .
. . . . . . . . 56Check the Running System . . . . . . . . . . . .
. . . . . . 56To Stop the Chiller . . . . . . . . . . . . . . . . .
. . . . . . . . . 57After Limited Shutdown . . . . . . . . . . . .
. . . . . . . . . 57Extended Shutdown . . . . . . . . . . . . . . .
. . . . . . . . . . 57After Extended Shutdown . . . . . . . . . . .
. . . . . . . . 57Cold Weather Operation . . . . . . . . . . . . .
. . . . . . . . 57Manual Guide Vane Operation . . . . . . . . . . .
. . . . 57Refrigeration Log . . . . . . . . . . . . . . . . . . . .
. . . . . . . 57PUMPOUT AND REFRIGERANTTRANSFER PROCEDURES . . . .
. . . . . . . . . . . . 59-61Preparation . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 59Operating the Optional
PumpoutCompressor . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 59 TO READ REFRIGERANT PRESSURESChillers with Pumpout
Storage Tanks . . . . . . . . 59 TRANSFER REFRIGERANT FROMSTORAGE
TANK TO CHILLER
TRANSFER THE REFRIGERANT FROMCHILLER TO STORAGE TANK
Chillers with Isolation Valves . . . . . . . . . . . . . . . .
60 TRANSFER ALL REFRIGERANT TOCHILLER CONDENSER VESSEL
TRANSFER ALL REFRIGERANT TO CHILLERCOOLER/COMPRESSOR VESSEL
RETURN REFRIGERANT TO NORMALOPERATING CONDITIONS
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . .
61,62Refrigerant Properties . . . . . . . . . . . . . . . . . . . .
. . . 61Adding Refrigerant . . . . . . . . . . . . . . . . . . . .
. . . . . . 61Removing Refrigerant . . . . . . . . . . . . . . . .
. . . . . . . 61Adjusting the Refrigerant Charge . . . . . . . . .
. . . 61Refrigerant Leak Testing . . . . . . . . . . . . . . . . .
. . . 61Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 61Test After Service, Repair, or Major Leak . . .
. . 61 REFRIGERANT TRACER TO PRESSURIZE WITH DRY NITROGENRepair the
Leak, Retest, and ApplyStanding Vacuum Test . . . . . . . . . . . .
. . . . . . . . 62
Checking Guide Vane Linkage . . . . . . . . . . . . . . . 62
CHECKING THE AUXILIARY SWITCH ONGUIDE VANE ACTUATOR
Trim Refrigerant Charge . . . . . . . . . . . . . . . . . . . .
. 62WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . .
62Check the Lubrication System . . . . . . . . . . . . . . .
62SCHEDULED MAINTENANCE . . . . . . . . . . . . . . 63-65Service
Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63Inspect the Control Center . . . . . . . . . . . . . . . . . . .
63Check Safety and Operating ControlsMonthly . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . 63
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . .
. . . . 63Oil Specification . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 63Oil Changes . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 63 TO CHANGE THE OILRefrigerant Filter .
. . . . . . . . . . . . . . . . . . . . . . . . . . . 63Oil Reclaim
Filters . . . . . . . . . . . . . . . . . . . . . . . . . .
63Inspect Refrigerant Float System . . . . . . . . . . . .
64Inspect Relief Valves and Piping . . . . . . . . . . . . .
64Compressor Bearing and GearMaintenance . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 64Inspect the Heat Exchanger
Tubes . . . . . . . . . . . 64 COOLER CONDENSER
3
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CONTENTS (cont)Page
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 64Water Treatment . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 65Inspect the Starting Equipment . . . . . . . .
. . . . . . 65Check Pressure Transducers . . . . . . . . . . . . .
. . . 65Optional Pumpout System Maintenance . . . . . . 65 OPTIONAL
PUMPOUT COMPRESSOR OILCHARGE
OPTIONAL PUMPOUT SAFETY CONTROLSETTINGS
Ordering Replacement Chiller Parts . . . . . . . . . .
65TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . 66-97Overview
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 66Checking the Display Messages . . . . . . . . . . . . .
66Checking Temperature Sensors . . . . . . . . . . . . . . 66
RESISTANCE CHECK VOLTAGE DROP CHECK SENSOR ACCURACY DUAL
TEMPERATURE SENSORSChecking Pressure Transducers . . . . . . . . .
. . . . 66 TRANSDUCER REPLACEMENTControl Algorithms Checkout
Procedure . . . . . 67Control Test . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 67
PageControl Modules . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 78 RED LED GREEN LEDsNotes on Module Operation . . . .
. . . . . . . . . . . . . . 78Processor Module (PSIO) . . . . . . .
. . . . . . . . . . . . . 79 INPUTS OUTPUTSStarter Management
Module (SMM) . . . . . . . . . . 79 INPUTS OUTPUTSOptions Modules
(8-Input) . . . . . . . . . . . . . . . . . . . 79Replacing
Defective Processor Modules . . . . . . 80 INSTALLATIONSolid-State
Starters . . . . . . . . . . . . . . . . . . . . . . . . . 81
TESTING SILICON CONTROL RECTIFIERSIN BENSHAW, INC. SOLID-STATE
STARTERS
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 85INDEX . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 98,99INITIAL START-UP CHECKLIST FOR19XL
HERMETIC CENTRIFUGALLIQUID CHILLER . . . . . . . . . . . . . . . .
. . . CL-1-CL-12
INTRODUCTIONPrior to initial start-up of the 19XL unit, those
involved in
the start-up, operation, and maintenance should be thor-oughly
familiar with these instructions and other necessaryjob data. This
book is outlined so that you may becomefamiliar with the control
system before performing start-upprocedures. Procedures in this
manual are arranged in thesequence required for proper chiller
start-up and operation.
This unit uses a microprocessor control system. Do notshort or
jumper between terminations on circuit boardsor modules; control or
board failure may result.Be aware of electrostatic discharge
(static electricity) whenhandling or making contact with circuit
boards or mod-ule connections. Always touch a chassis (grounded)
partto dissipate body electrostatic charge before workinginside
control center.Use extreme care when handling tools near boards
andwhen connecting or disconnecting terminal plugs. Cir-cuit boards
can easily be damaged. Always hold boardsby the edges and avoid
touching components andconnections.This equipment uses, and can
radiate, radio frequencyenergy. If not installed and used in
accordance withthe instruction manual, it may cause interference
toradio communications. It has been tested and found tocomply with
the limits for a Class A computing devicepursuant to Subpart J of
Part 15 of FCC (Federal Com-munication Commission) Rules, which are
designed toprovide reasonable protection against such
interferencewhen operated in a commercial environment. Operationof
this equipment in a residential area is likely to
causeinterference, in which case the user, at his own expense,will
be required to take whatever measures may be re-quired to correct
the interference.Always store and transport replacement or
defective boardsin anti-static shipping bag.
ABBREVIATIONS AND EXPLANATIONSFrequently used abbreviations in
this manual include:
CCN Carrier Comfort NetworkCCW CounterclockwiseCW ClockwiseECW
Entering Chilled WaterECDW Entering Condenser WaterEMS Energy
Management SystemHGBP Hot Gas BypassI/O Input/OutputLCD Liquid
Crystal DisplayLCDW Leaving Condenser WaterLCW Leaving Chilled
WaterLED Light-Emitting DiodeLID Local Interface DeviceOLTA
Overload Trip AmpsPIC Product Integrated ControlPSIO Processor
Sensor Input/Output ModuleRLA Rated Load AmpsSCR Silicon Control
RectifierSI International System of UnitsSMM Starter Management
ModuleTXV Thermostatic Expansion Valve
The 19XL chillers use HCFC-22 and HFC-134a refrig-erant. When
referencing refrigerant charges in this manual,the HCFC-22 charge
will be listed first and the HFC-134avalue will be shown next to it
in brackets [ ].Words printed in all capital letters and italics
represent val-
ues that may be viewed on the LID.The PSIO software version
number of your 19XL unit will
be located on the front cover.
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CHILLER FAMILIARIZATION(Fig. 1, 2A, and 2B)
Chiller Information Plate The information plateis located on the
right side of the chiller control centerpanel.
System Components The components include thecooler and condenser
heat exchangers in separate vessels,motor-compressor, lubrication
package, control center, andmotor starter. All connections from
pressure vessels have ex-ternal threads to enable each component to
be pressure testedwith a threaded pipe cap during factory
assembly.
Cooler This vessel (also known as the evaporator) islocated
underneath the compressor. The cooler is main-tained at lower
temperature/pressure so that evaporatingrefrigerant can remove heat
from water flowing through itsinternal tubes.
Condenser The condenser operates at a highertemperature/pressure
than the cooler, and has water flowingthrough its internal tubes in
order to remove heat from therefrigerant.
Motor-Compressor This component maintains sys-tem
temperature/pressure differences and moves the heatcarrying
refrigerant from the cooler to the condenser.
Control Center The control center is the user inter-face for
controlling the chiller. It regulates the chillerscapacity as
required to maintain proper leaving chilled watertemperature. The
control center: registers cooler, condenser, and lubricating
systempressures
shows chiller operating condition and alarm
shutdownconditions
records the total chiller operating hours sequences chiller
start, stop, and recycle under micro-processor control
provides access to other CCN (Carrier Comfort
Network)devices
Factory-Mounted Starter (Optional) The starterallows the proper
start and disconnect of electrical energyfor the compressor-motor,
oil pump, oil heater, and controlpanels.
Storage Vessel (Optional) There are 2 sizesof storage vessels
available. The vessels have double relief
valves, a magnetically coupled dial-type refrigerant levelgage,
a one-inch FPT drain valve, and a 12-in. male flarevapor connection
for the pumpout unit. A 30-in.-0-400 psi(101-0-2750 kPa) gage also
is supplied with each unit.NOTE: If a storage vessel is not used at
the jobsite, factory-installed isolation valves on the chiller may
be used to iso-late the chiller charge in either the cooler or
condenser.An optional pumpout compressor system is used to
transferrefrigerant from vessel to vessel.
REFRIGERATION CYCLEThe compressor continuously draws refrigerant
vapor from
the cooler, at a rate set by the amount of guide vane opening.As
the compressor suction reduces the pressure in the cooler,the
remaining refrigerant boils at a fairly low temperature(typically
38 to 42 F [3 to 6 C]). The energy required forboiling is obtained
from the water flowing through the coolertubes. With heat energy
removed, the water becomes coldenough for use in an air
conditioning circuit or process liq-uid cooling.After taking heat
from the water, the refrigerant vapor
is compressed. Compression adds still more heat energyand the
refrigerant is quite warm (typically 98 to 102 F[37 to 40 C]) when
it is discharged from the compressor intothe condenser.Relatively
cool (typically 65 to 90 F [18 to 32 C]) water
flowing into the condenser tubes removes heat from
therefrigerant and the vapor condenses to liquid.The liquid
refrigerant passes through orifices into the
FLASC (Flash Subcooler) chamber (Fig. 3). Since the FLASCchamber
is at a lower pressure, part of the liquid refrigerantflashes to
vapor, thereby cooling the remaining liquid. TheFLASC vapor is
recondensed on the tubes which are cooledby entering condenser
water. The liquid drains into a floatchamber between the FLASC
chamber and cooler. Here afloat valve forms a liquid seal to keep
FLASC chambervapor from entering the cooler.When liquid refrigerant
passesthrough the valve, some of it flashes to vapor in the
reducedpressure on the cooler side. In flashing, it removes heat
fromthe remaining liquid. The refrigerant is now at a
temperatureand pressure at which the cycle began.
MOTOR/OIL REFRIGERATIONCOOLING CYCLE
The motor and the lubricating oil are cooled by
liquidrefrigerant taken from the bottom of the condenser
vessel(Fig. 3). Flow of refrigerant is maintained by the
pressuredifferential that exists due to compressor operation.After
therefrigerant flows past an isolation valve, an in-linefilter, and
a sight glass/moisture indicator, the flow is splitbetween motor
cooling and oil cooling systems.Flow to the motor flows through an
orifice and into the
motor. There is also another orifice and a solenoid valve
whichwill open if additional motor cooling is required. Once
pastthe orifice, the refrigerant is directed over the motor by
aspray nozzle. The refrigerant collects in the bottom of themotor
casing and then is drained back into the cooler throughthe motor
refrigerant drain line. A back pressure valve or anorifice in this
line maintains a higher pressure in the motorshell than in the
cooler/oil sump. The motor is protected bya temperature sensor
imbedded in the stator windings. Highermotor temperatures (above
125 F [51 C]) energize a sole-noid to provide additional motor
cooling. A further increasein temperature past the motor override
set point will over-ride the temperature capacity control to hold,
and if themotor temperature rises 10 F (5.5 C) above this set
point,will close the inlet guide vanes. If the temperature rises
abovethe safety limit, the compressor will shut down.
Fig. 1 19XL Identification
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19XL FRONT VIEW
19XL REAR VIEW
Fig. 2A Typical 19XL Components Design I
LEGEND1 Unit-Mounted Starter2 Refrigerant Filter Drier3 Rigging
Guide Bolt4 Refrigerant Moisture Indicator5 Motor Sight Glass6
Refrigerant Motor Drain7 Oil Filter Access Cover8 Refrigerant Oil
Cooler9 Oil Level Sight Glasses10 Guide Vane Actuator11 Typical
Flange Connection12 Control Center13 ASME Nameplate, Cooler14
Take-Apart, Rabbet Fit Connector
(Lower)15 Refrigerant Charging Valve16 Cooler Refrigerant
Isolation Valve17 Cooler Pressure Schrader Fittings18 Oil
Drain/Charging Valve19 Power Panel20 Retro-Fit, Rig-in-Place
Beams21 Typical Waterbox Drain Port22 Take-Apart, Shell Leveling
Feet23 Cooler Return-End Waterbox Cover24 ASME Nameplate,
Condenser25 Condenser Return-End Waterbox Cover26 Take-Apart,
Rabbet Fit Connector
(Upper)27 Protective Truck Holddown Lugs28 Refrigerant Cooling
Isolation Valve
(Hidden)
LEGEND29 Pumpdown System Connection30 Cooler Relief Valves31
Chiller Identification Nameplate32 Cooler Pressure Transducer33
Suction Elbow34 Transmission Vent Line35 Discharge Pressure Switch
and
Discharge Pressure Transducer36 Condenser Isolation Valve37
Low-Voltage Access Door, Starter38 Medium-Voltage Access Door,
Starter39 Amp/Volt Gages40 Refrigerant Supply Sump41 Condenser
Pressure Transducer42 Liquid Seal Float Chamber43 ASME Nameplate,
Float Chamber44 Condenser Relief Valves45 Condenser In/Out
Temperature Sensors46 Cooler In/Out Temperature Sensors
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4 5 6 7 8 9 10 11
12
13
1415161718192021
22
2324
19XL FRONT VIEW
31
302928272625
41
40
39
38 37 36 35 34 33
32
15
42
19XL REAR VIEW
Fig. 2B Typical 19XL Components Design II
LEGEND1 Unit-Mounted Starter2 Refrigerant Filter Drier3 Rigging
Guide Bolt4 Motor Sight Glass5 Refrigerant Moisture Indicator6
Refrigerant Oil Cooler7 Oil Filter Access Cover8 Oil Level Sight
Glasses9 Guide Vane Actuator10 Typical Flange Connection11 Control
Center12 Cooler Pressure Schrader Fitting
(Hidden)13 ASME Nameplate, Cooler14 Cooler15 Take-Apart Rabbet
Fit Connector
(Lower)16 Refrigerant Charging Valve17 Oil Drain/Charging
Valve18 Power Panel19 Cooler Waterbox Cover20 Cooler In/Out
Temperature Sensors21 Condenser In/Out Temperature Sensors22
Condenser Waterbox Cover23 Take-Apart Rabbet Fit Connector
(Upper)24 Refrigerant Cooling Isolation Valve
(Hidden)
LEGEND25 Cooler Relief Valve26 Chiller Identification Plate27
Suction Elbow28 Transmission Vent Line29 Condenser Relief Valves30
Low Voltage Access Door, Starter31 Medium Voltage Access Door,
Starter32 Amp/Volt Gages33 Condenser Isolation Valve34 Linear Float
Valve Chamber35 Condenser Pressure Transducer36 Discharge Pressure
Switch and
Discharge Pressure Transducer37 Cooler Refrigerant Isolation
Valve38 Condenser Return End Waterbox Cover39 Typical Waterbox
Drain Port40 Cooler Return End Waterbox Cover41 Cooler Pressure
Transducer42 Pumpdown Valve
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Refrigerant that flows to the oil cooling system is reg-ulated
by a thermostatic expansion valve. There is alwaysa minimum flow
bypassing the TXV, which flows throughan orifice. The TXV valve
regulates flow into the oil/refrigerant plate and frame-type heat
exchanger. The bulbfor the expansion valve controls oil temperature
to the bear-ings. The refrigerant leaving the heat exchanger then
returnsto the cooler.
LUBRICATION CYCLESummary The oil pump, oil filter, and oil
cooler makeup a package located partially in the transmission
casting ofthe compressor-motor assembly. The oil is pumped into
afilter assembly to remove foreign particles, and is then
forcedinto an oil cooler heat exchanger where the oil is cooled
toproper operational temperatures. After the oil cooler, part ofthe
flow is directed to the gears and the high speed shaftbearings; the
remaining flow is directed to the motor shaftbearings. Oil drains
into the transmission oil sump to com-plete the cycle (Fig.
4).Details Oil is charged into the lubrication system througha hand
valve. Two sight glasses in the oil reservoir permit oillevel
observation. Normal oil level is between the middle ofthe upper
sight glass and the top of the lower sight glass
when the compressor is shut down. The oil level should bevisible
in at least one of the 2 sight glasses during operation.Oil sump
temperature is displayed on the LID defaultscreen. Oil sump
temperature ranges during compressoroperation between 100 to 120 F
(37 to 49 C) [120 to 140 F(49 to 60 C)].The oil pump suction is fed
from the oil reservoir. An
oil pressure relief valve maintains 18 to 25 psid (124 to172
kPad) differential pressure in the system at the pumpdischarge.
This differential pressure can be read directly fromthe Local
Interface Device (LID) default screen. The oil pumpdischarges oil
to the oil filter assembly. This filter can bevalved closed to
permit removal of the filter without drain-ing the entire oil
system (see Maintenance sections, pages61 to 65, for details). The
oil is then piped to the oil cooler.This heat exchanger uses
refrigerant from the condenser asthe coolant. The refrigerant cools
the oil to a temperaturebetween 100 and 120 F (37 to 49 C).As the
oil leaves the oil cooler, it passes the oil pressure
transducer and the thermal bulb for the refrigerant expan-sion
valve on the oil cooler. The oil is then divided, with aportion
flowing to the thrust bearing, forward pinion bear-ing, and gear
spray. The balance then lubricates the motorshaft bearings and the
rear pinion bearing. The oil temper-ature is measured as the oil
leaves the thrust and forward
Fig. 3 Refrigerant Motor Cooling and Oil Cooling Cycles
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journal bearings within the bearing housing. The oil then
drainsinto the oil reservoir at the base of the compressor. The
PIC(Product Integrated Control) measures the temperature of theoil
in the sump and maintains the temperature during shut-down (see Oil
Sump Temperature Control section, page 32).This temperature is read
on the LID default screen.During the chiller start-up, the PIC will
energize the oil
pump and provide 15 seconds of prelubrication to the bear-ings
after pressure is verified before starting the compressor.During
shutdown, the oil pump will run for 60 seconds topost-lubricate
after the compressor shuts down. The oil pumpcan also be energized
for testing purposes in the Control Test.Ramp loading can slow the
rate of guide vane opening
to minimize oil foaming at start-up. If the guide vanesopen
quickly, the sudden drop in suction pressure can causeany
refrigerant in the oil to flash. The resulting oil foamcannot be
pumped efficiently; therefore, oil pressure fallsoff and
lubrication is poor. If oil pressure falls below15 psid (103 kPad)
differential, the PIC will shut down thecompressor.
Oil Reclaim System The oil reclaim system oper-ates to return
oil back to the oil reservoir by recovering itfrom 2 areas on the
chiller. The primary area of recovery isfrom the guide vane
housing. Oil also is recovered, alongwith refrigerant, from the
cooler.Any refrigerant that enters the oil
reservoir/transmission
area is flashed into gas. The demister line at the top of
the
casing will vent this refrigerant into the suction of the
com-pressor. Oil entrained in the refrigerant is eliminated by
thedemister filter.DURING NORMAL CHILLER OPERATION, oil isentrained
with the refrigerant. As the compressor pullsthe refrigerant into
the guide vane housing to be com-pressed, the oil will normally
drop out at this point andfall to the bottom of the housing where
it accumulates. Us-ing discharge gas pressure to power an eductor,
the oil isvacuumed from the housing by the eductor and is
dis-charged into the oil reservoir. Oil and refrigerant are
alsorecovered from the top of the cooler refrigerant level and
aredischarged into the guide vane housing. The oil will drop tothe
bottom of the guide vane housing and be recovered bythe eductor
system.DURING LIGHTLOADCONDITIONS, the suction gas intothe
compressor does not have enough velocity to return oil,which is
floating in the cooler back to the compressor. Inaddition, the
eductor may not have enough power to pull theoil from the guide
vane housing back into the oil reservoirdue to extremely low
pressure at the guide vanes. Two so-lenoids, located on the oil
reclaim piping, are operated sothat the eductor can pull oil and
refrigerant directly from thecooler and discharge the mixture into
the oil reservoir. Theoil reclaim solenoids are operated by an
auxiliary contactintegral to the guide vane actuator. This
switchover of thesolenoids occurs when the guide vanes are opened
beyond30 degrees from the closed position.
Fig. 4 Lubrication System
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STARTING EQUIPMENTThe 19XL requires a motor starter to operate
the centrif-
ugal hermetic compressor motor, the oil pump, and
variousauxiliary equipment. The starter serves as the main
fieldwiring interface for the contractor.Three types of starters
are available from Carrier Cor-
poration: solid-state, wye-delta, and across-the-line
starters.See Carrier Specification Z-375 for specific starter
require-ments. All starters must meet these specifications in
orderto properly start and satisfy mechanical safety
requirements.Starters may be supplied as separate, free-standing
units, ormay be mounted directly on the chiller (unit mounted)
forlow-voltage units only.Inside the starter are 3 separate circuit
breakers. Circuit
breaker CB1 is the compressor motor circuit breaker.
Thedisconnect switch on the starter front cover is connected tothis
breaker. Circuit breaker CB1 supplies power to the com-pressor
motor.
The main circuit breaker (CB1) on the front of the
starterdisconnects the main motor current only. Power is
stillenergized for the other circuits. Two more circuit break-ers
inside the starter must be turned off to disconnectpower to the oil
pump, PIC controls, and oil heater.Circuit breaker CB2 supplies
power to the control center,
oil heater, and portions of the starter controls. Circuit
breakerCB3 supplies power to oil pump. Both of these circuit
break-ers are wired in parallel with CB1 so that power is
suppliedto them if the CB1 disconnect is open.All starters are
shipped with a Carrier control module called
the Starter Management Module (SMM). This modulecontrols and
monitors all aspects of the starter. See the Con-trols section on
page 11 for additional SMM information.All starter replacement
parts are supplied by the startermanufacturer.
Unit-Mounted Solid-State Starter (Optional) The 19XL may be
equipped with a solid-state, reduced-voltage starter (Fig. 5 and
6). This starter provides on-offcontrol of the compressor motor as
its primary function.Using this type of starter reduces the peak
starting torque,reduces the motor inrush current, and decreases
mechanicalshock. This is summed up by the phrase soft starting.Two
varieties of solid-state starters are available as a 19XL
option (factory supplied and installed).When a
unit-mounted,optional, solid-state starter is purchased with the
19XL, aBenshaw, Inc. solid-state starter will be shipped with the
unit.See Fig. 5. The solid-state starters manufacturer name willbe
located inside the starter access door. See Fig. 6.These starters
operate by reducing the starting voltage. The
starting torque of a motor at full voltage is typically 125%to
175% of the running torque. When the voltage and thecurrent are
reduced at start-up, the starting torque is reducedas well. The
object is to reduce the starting voltage to justthe voltage
necessary to develop the torque required to getthe motor moving.
The voltage and current are then rampedup in a desired period of
time. The voltage is reduced throughthe use of silicon controlled
rectifiers (SCR). Once full volt-age is reached, a bypass contactor
is energized to bypass theSCRs.
When voltage is supplied to the solid-state circuitry, theheat
sinks within the starter are at line voltage. Do nottouch the heat
sinks while voltage is present or seriousinjury will result.
There are a number of LEDs (light-emitting diodes) thatare
useful in troubleshooting and starter check-out onBenshaw, Inc.
solid-state starters. These are used toindicate: voltage to the
SCRs SCR control voltage power indication proper phasing for
rotation start circuit energized
LEGEND1 Field Wiring Terminal Strips (TB2 and TB3)2 Circuit
Breaker 1, 2, 3, 43 Overload Unit4 Solid-State Controller5 Silicon
Controlled Rectifier (SCR) LED (One of 6)6 Starter Fault and Run
LEDs7 Voltmeter (Optional)8 Ammeter (Optional)9 SCR (One of 6)10
Voltage LED11 Starter Management Module (SMM)12 Pilot Relays (PR1
to PR5)13 Starter Access Door
Fig. 5 Benshaw, Inc. Solid-State Starter,Internal View
Fig. 6 Typical Starter External View(Solid-State Starter
Shown)
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overtemperature ground fault current unbalance run stateThese
LEDs are further explained in the Check Starter and
Troubleshooting Guide section, page 66.
Unit-MountedWye-DeltaStarter (Optional) The19XLchiller may be
equippedwith a wye-delta starter mountedon the unit (Fig. 7). This
starter is intended for use with low-voltage motors (under 600 v).
It reduces the starting currentinrush by connecting each phase of
the motor windings intoa wye configuration. This occurs during the
starting periodwhen the motor is accelerating up to speed. After a
time de-lay, once the motor is up to speed, the starter
automaticallyconnects the phase windings into a delta
configuration.
CONTROLSDefinitionsANALOG SIGNAL An analog signal varies in
propor-tion to the monitored source. It quantifies values
betweenoperating limits. (Example: A temperature sensor is an
ana-log device because its resistance changes in proportion tothe
temperature, generating many values.)DIGITALSIGNALAdigital
(discrete) signal is a 2-positionrepresentation of the value of a
monitored source. (Ex-ample: A switch is a digital device because
it only indicateswhether a value is above or below a set point or
boundaryby generating an on/off, high/low, or open/closed
signal.)VOLATILE MEMORY Volatile memory is memory in-capable of
being sustained if power is lost and subsequentlyrestored.
The memory of the PSIO and LID modules are volatile.If the
battery in a module is removed or damaged, allprogramming will be
lost.
General The 19XL hermetic centrifugal liquid chillercontains a
microprocessor-based control center that moni-tors and controls all
operations of the chiller. The micro-processor control system
matches the cooling capacity of thechiller to the cooling load
while providing state-of-the-artchiller protection. The system
controls cooling load withinthe set point plus the deadband by
sensing the leaving chilledwater or brine temperature, and
regulating the inlet guidevane via a mechanically linked actuator
motor. The guidevane is a variable flow prewhirl assembly that
controls therefrigeration effect in the cooler by regulating the
amount ofrefrigerant vapor flow into the compressor. An increase
inguide vane opening increases capacity. A decrease in guidevane
opening decreases capacity. Chiller protection is pro-vided by the
processor which monitors the digital and ana-log inputs and
executes capacity overrides or safety shutdowns,if required.
PIC System Components The Product IntegratedControl (PIC) is the
control system on the chiller. SeeTable 1. The PIC controls the
operation of the chiller by moni-toring all operating conditions.
The PIC can diagnose a prob-lem and let the operator know what the
problem is and whatto check. It promptly positions the guide vanes
to maintainleaving chilled water temperature. It can interface with
aux-iliary equipment such as pumps and cooling tower fans toturn
them on only when required. It continually checks allsafeties to
prevent any unsafe operating condition. It alsoregulates the oil
heater while the compressor is off, and thehot gas bypass valve, if
installed.The PIC can be interfaced with the Carrier Comfort
Net-
work (CCN) if desired. It can communicate with other
PIC-equipped chillers and other CCN devices.The PIC consists of 3
modules housed inside the 3 major
components. The component names and the control voltagecontained
in each component are listed below (also seeTable 1): control
center all extra low-voltage wiring (24 v or less) power panel 230
or 115 v control voltage (per job
requirement) up to 600 v for oil pump power
starter cabinet chiller power wiring (per jobrequirement)
Table 1 Major PIC Components andPanel Locations*
PIC COMPONENT PANELLOCATIONProcessor Sensor Input/Output
Module(PSIO) Control CenterStarter Management Module (SMM) Starter
CabinetLocal Interface Device (LID) Control Center6-Pack Relay
Board Control Center8-Input Modules (Optional) Control CenterOil
Heater Contactor (1C) Power PanelOil Pump Contactor (2C) Power
PanelHot Gas Bypass Relay (3C) (Optional) Power PanelControl
Transformers (T1-T4) Power PanelControl and Oil Heater Voltage
Selector (S1) Power PanelTemperature Sensors See Fig. 8Pressure
Transducers See Fig. 8*See Fig. 5, 6, and Fig. 8-12.
1 2 3 4 5 6 7
1011121314
15
16
17
9
8
LEGEND1 Pilot Relays2 SMM Power Circuit Breaker and Voltage
Calibration
Potentiometer3 Transistor Resistor Fault Protector (TRFP)4
Transformer (T2)5 Control Power Circuit Breaker6 Oil Pump Circuit
Breaker7 Main Circuit Breaker Disconnect8 Voltmeter (Optional)9
Ammeter (Optional)10 Current Transformers (T1, T2, T3)11 Phase
Monitor Relay (Optional)12 Overload Unit13 Starter Management
Module14 Starter Access Door15 Control Transformer Secondary
Circuit Breaker16 Signal Resistor17 Field Wiring Terminal Strip
(TB6)
Fig. 7 Wye-Delta Starter, Internal View
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Fig. 8 19XL Controls and Sensor Locations
Fig. 9 Control Sensors(Temperature)
Fig. 10 Control Sensors(Pressure Transducer, Typical)
LEGEND1 LID2 PSIO3 8-Input Module (One of 2 Available)4 5-Volt
Transducer Power Supply5 6-Pack Relay Board6 Circuit Breakers
(4)
Fig. 11 Control Center (Front View),with Options Module
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PROCESSOR MODULE (PSIO) The PSIO is the brainof the PIC (Fig.
11). This module contains all the operatingsoftware needed to
control the chiller. The 19XL uses 3 pres-sure transducers and 8
thermistors to sense pressures and tem-peratures. These are
connected to the PSIOmodule. The PSIOalso provides outputs to the
guide vane actuator, oil pump,oil heater, hot gas bypass
(optional), motor cooling solenoid,and alarm contact. The PSIO
communicates with the LID,the SMM, and the optional 8-input modules
for user inter-face and starter management.STARTERMANAGEMENTMODULE
(SMM)Thismod-ule is located within the starter cabinet. This module
ini-tiates PSIO commands for starter functions such as start/stop
of the compressor, start/stop of the condenser and chilledwater
pumps, start/stop of the tower fan, spare alarm con-tacts, and the
shunt trip. The SMM monitors starter inputssuch as flow switches,
line voltage, remote start contact, sparesafety, condenser high
pressure, oil pump interlock, motorcurrent signal, starter 1M and
run contacts, and kW trans-ducer input (optional). The SMM contains
logic capable ofsafely shutting down the machine if communications
withthe PSIO are lost.LOCALINTERFACEDEVICE (LID)The LID is
mountedto the control center and allows the operator to interface
withthe PSIO or other CCN devices (Fig. 11). It is the input
cen-ter for all local chiller set points, schedules, set-up
func-tions, and options. The LID has a STOP button, an alarmlight,
4 buttons for logic inputs, and a display. The functionof the 4
buttons or softkeys are menu driven and are shownon the display
directly above the key.6-PACK RELAY BOARD This device is a cluster
of6 pilot relays located in the control center (Fig. 11). It
isenergized by the PSIO for the oil pump, oil heater,
alarm,optional hot gas bypass relay, and motor cooling
solenoid.
8-INPUTMODULES One optional module is factory in-stalled in the
control center panel when ordered (Fig. 11).There can be up to 2 of
these modules per chiller with8 spare inputs each. They are used
whenever chilled waterreset, demand reset, or reading a spare
sensor is required.The sensors or 4 to 20 mA signals are
field-installed.The spare temperature sensors must have the
same
temperature/resistance curve as the other temperature sen-sors
on this unit. These sensors are 5,000 ohm at 75 F(25 C).OIL HEATER
CONTACTOR (1C) This contactor is lo-cated in the power panel (Fig.
12) and operates the heater ateither 115 or 230 v. It is controlled
by the PIC to maintainoil temperature during chiller shutdown.OIL
PUMPCONTACTOR (2C) This contactor is locatedin the power panel
(Fig. 12). It operates all 200 to 575-v oilpumps. The PIC energizes
the contactor to turn on the oilpump as necessary.HOT GAS BYPASS
CONTACTOR RELAY (3C) (Op-tional) This relay, located in the power
panel, (Item 5,Fig. 12) controls the opening of the hot gas bypass
valve.The PIC energizes the relay during low load, high
liftconditions.CONTROL TRANSFORMERS (T1-T4) These trans-formers
convert incoming control voltage to either 21 vacpower for the PSIO
module and options modules, or 24 vacpower for 3 power panel
contactor relays, 3 control solenoidvalves, and the guide vane
actuator. They are located in thepower panel. See Fig.
12.CONTROLANDOILHEATERVOLTAGESELECTOR (S1) It is possible to use
either 115 v or 230 v incoming con-trol power in the power panel.
The switch is set to the volt-age used at the jobsite.
LEGEND1 T2 24 vac Power Transformer for Hot Gas Bypass
Relay,
Oil Pump Relay, Oil Heater Relay, Motor Cooling Solenoid,Oil
Reclaim Solenoid
2 Oil Pressure Switch3 T4 24 vac, Optional 8-Input Module
Transformer
Fig. 12 Power Panel with Options
4 T1 24 vac, Control Center Transformer5 3C Hot Gas Bypass Relay
Location6 Oil Pump Terminal Block7 Factory Terminal Connections8 T3
24 vac Guide Vane Actuator Transformer
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LID Operation and Menus (Fig. 13-19)GENERAL The LID display will
automatically revert to the defaultscreen after 15 minutes if no
softkey activity takes placeand if the chiller is not in the
Pumpdown mode(Fig. 13).
When not in the default screen, the upper right-hand cor-ner of
the LID always displays the name of the screen thatyou have entered
(Fig. 14).
The LID may be configured in English or SI units, throughthe LID
configuration screen.
Local Operation By pressing the LOCAL softkey, thePIC is now in
the LOCAL operation mode. The controlwill accept changes to set
points and configurations fromthe LID only. The PIC will use the
Local Time Scheduleto determine chiller start and stop times.
CCN Operation By pressing the CCN softkey, the PICis now in the
CCN operation mode, and the control willaccept modifications from
any CCN interface or module(with the proper authority), as well as
the LID. The PICwill use the CCN time schedule to determine start
and stoptimes.
ALARMS AND ALERTS Alarm (*) and alert (!) statusare indicated on
the Status tables.An alarm (*) will shut downthe compressor. An
alert (!) notifies the operator that an un-usual condition has
occurred. The chiller will continue tooperate when an alert is
shown.Alarms are indicated when the control center alarm light
(!) flashes. The primary alarm message is viewed on the de-fault
screen and an additional, secondary, message andtroubleshooting
information are sent to the Alarm Historytable.When an alarm is
detected, the LID default screen will
freeze (stop updating) at the time of alarm. The freeze en-ables
the operator to view the chiller conditions at the timeof alarm.
The Status tables will show the updated informa-tion. Once all
alarms have been cleared (by pressing theRESET softkey), the
default LID screen will return to nor-mal operation.
MENU STRUCTURE To perform any of the operationsdescribed below,
the PIC must be powered up and have suc-cessfully completed its
self test. The self test takes placeautomatically, after
power-up.
Press QUIT to leave the selected decision or field with-out
saving any changes.
Press ENTER to leave the selected decision or field andsave
changes.
Press NEXT to scroll the cursor bar down in order tohighlight a
point or to view more points below the currentscreen.
Press PREVIOUS to scroll the cursor bar up in order tohighlight
a point or to view points above the current screen.
Press SELECT to view the next screen level (high-lighted with
the cursor bar), or to override (if allowable)the highlighted point
value.
Fig. 13 LID Default Screen
Fig. 14 LID Service Screen
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Press EXIT to return to the previous screen level.
Press INCREASE or DECREASE to change the high-lighted point
value.
TO VIEW POINT STATUS (Fig. 15) Point Status is theactual value
of all of the temperatures, pressures, relays, andactuators sensed
and controlled by the PIC.1. On the Menu screen, press STATUS to
view the list of
Point Status tables.
2. Press NEXT or PREVIOUS to highlight the desiredstatus table.
The list of tables is: Status01 Status of control points and
sensors Status02 Status of relays and contacts Status03 Status of
both optional 8-input modules and
sensors
3. Press SELECT to view the Point Status table desired.
4. On the Point Status table press NEXT orPREVIOUS until desired
point is displayed on the screen.
OVERRIDE OPERATIONSTo Override a Value or Status1. On the Point
Status table press NEXT or
PREVIOUS to highlight the desired point.
2. Press SELECT to select the highlighted point. Then:
For Discrete Points Press START or STOP to se-lect the desired
state.
For Analog Points Press INCREASE orDECREASE to select the
desired value.
3. Press ENTER to register new value.
NOTE: When overriding or changing metric values, it isnecessary
to hold the softkey down for a few seconds in or-der to see a value
change, especially on kilopascalvalues.
To Remove an Override1. On the Point Status table press NEXT
or
PREVIOUS to highlight the desired point.
2. Press SELECT to access the highlighted point.
Fig. 15 Example of Point Status Screen(Status01)
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3. Press RELEASE to remove the override and return thepoint to
the PICs automatic control.
Override Indication An override value is indicated bySUPVSR,
SERVC,or BESTflashing next to the pointvalue on the Status
table.
TIME SCHEDULE OPERATION (Fig. 16)1. On the Menu screen, press
SCHEDULE .
2. Press NEXT or PREVIOUS to highlight the de-sired
schedule.PSIO Software Version 08 and lower:OCCPC01S LOCAL Time
ScheduleOCCPC02S CCN Time Schedule
PSIO Software Version 09 and higher:OCCPC01S LOCAL Time
ScheduleOCCPC02S ICE BUILD Time ScheduleOCCPC03-99S CCN Time
Schedule (Actual
number is defined inConfig table.)
3. Press SELECT to access and view the time schedule.
4. Press NEXT or PREVIOUS to highlight the de-sired period or
override that you wish to change.
5. Press SELECT to access the highlighted period oroverride.
6. a. Press INCREASE or DECREASE to change thetime values.
Override values are in one-hour incre-ments, up to 4 hours.
b. Press ENABLE to select days in the day-of-weekfields. Press
DISABLE to eliminate days from theperiod.
7. Press ENTER to register the values and to movehorizontally
(left to right) within a period.
8. Press EXIT to leave the period or override.
9. Either return to Step 4 to select another period oroverride,
or press EXIT again to leave the current timeschedule screen and
save the changes.
10. Holiday Designation (HOLIDEF table) may be found inthe
Service Operation section, page 38. You must assignthe month, day,
and duration for the holiday. The Broad-cast function in the
Brodefs table also must be enabledfor holiday periods to
function.
Fig. 16 Example of Time ScheduleOperation Screen
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*OnlyavailableonPS
IOSo
ftwareVe
rsion09
andhigher.
AvailableonPS
IOSo
ftwareVe
rsions
07and08.
Fig.
17
19XL
MenuStructure
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Fig.
18
19XL
ServiceMenuStructure
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*OnlyavailableonPS
IOSo
ftwareVe
rsion09
andhigher.
AvailableonPS
IOSo
ftwareVe
rsions
07and08.
Fig.
18
19XL
ServiceMenuStructure(co
nt)
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TO VIEW AND CHANGE SET POINTS (Fig. 19)1. To view the Set Point
table, at the Menu screen press
SETPOINT .
2. There are 4 set points on this screen: Base Demand Limit;LCW
Set Point (leaving chilled water set point); ECWSet Point (entering
chilled water set point); and ICEBUILDset point (PSIO Software
Version 09 and higher only).Only one of the chilled water set
points can be active atone time, and the type of set point is
activated in the Serv-ice menu. ICE BUILD is also activated and
configured inthe Service menu.
3. Press NEXT or PREVIOUS to highlight the desiredset point
entry.
4. Press SELECT to modify the highlighted set point.
5. Press INCREASE or DECREASE to change the se-lected set point
value.
6. Press ENTER to save the changes and return to theprevious
screen.
SERVICE OPERATION To view the menu-driven pro-grams available
for Service Operation, see Service Opera-tion section, page 38. For
examples of LID display screens,see Table 2.
Fig. 19 Example of Set Point Screen
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Table 2 LID Screens
NOTES:1. Only 12 lines of information appear on the LID screen
at any given time. Press NEXT or PREVIOUS to highlight a point or
to view points
below or above the current screen.2. The LID may be configured
in English or SI units, as required, through the LID configuration
screen.3. Data appearing in the Reference Point Names column is
used for CCN operations only.4. All options associated with ICE
BUILD, Lead/Lag, CCN Occupancy Configuration, and Soft Stopping are
only available on PSIO Software
Version 9 and higher.
EXAMPLE 1 STATUS01 DISPLAY SCREENTo access this display from the
LID default screen:1. Press MENU .
2. Press STATUS (STATUS01 will be highlighted).3. Press SELECT
.
DESCRIPTION RANGE UNITS REFERENCE POINT NAME(ALARM
HISTORY)Control Mode Reset, Off, Local, CCN MODE
Run StatusTimeout, Recycle, Startup,Ramping, Running, Demand,
Override,Shutdown, Abnormal, Pumpdown
STATUS
Occupied ? No/Yes OCCAlarm State Normal/Alarm ALM*Chiller
Start/Stop Stop/Start CHIL S SBase Demand Limit 40-100 % DLM*Active
Demand Limit 40-100 % DEM LIMCompressor Motor Load 0-999 % CA L
Current 0-999 % CA PAmps 0-999 AMPS CA A
*Target Guide Vane Pos 0-100 % GV TRGActual Guide Vane Pos 0-100
% GV ACTWater/Brine: Setpoint 10-120 (12.2-48.9) DEG F (DEG C) SP*
Control Point 10-120 (12.2-48.9) DEG F (DEG C) LCW STPTEntering
Chilled Water 40-245 (40-118) DEG F (DEG C) ECWLeaving Chilled
Water 40-245 (40-118) DEG F (DEG C) LCWEntering Condenser Water
40-245 (40-118) DEG F (DEG C) ECDWLeaving Condenser Water 40-245
(40-118) DEG F (DEG C) LCDWEvaporator Refrig Temp 40-245 (40-118)
DEG F (DEG C) ERTEvaporator Pressure 6.7-420 (46-2896) PSI (kPa)
ERPCondenser Refrig Temp 40-245 (40-118) DEG F (DEG C) CRTCondenser
Pressure 6.7-420 (46-2896) PSI (kPa) CRPDischarge Temperature
40-245 (40-118) DEG F (DEG C) CMPDBearing Temperature 40-245
(40-118) DEG F (DEG C) MTRBMotor Winding Temp 40-245 (40-118) DEG F
(DEG C) MTRWOil Sump Temperature 40-245 (40-118) DEG F (DEG C)
OILTOil Pressure Transducer 6.7-420 (46-2896) PSI (kPa) OILPOil
Pressure 6.7-420 (46-2896) PSID (kPad) OILPDLine Voltage: Percent
0-999 % V P
Actual 0-9999 VOLTS V A*Remote Contacts Input Off/On REMCONTotal
Compressor Starts 0-65535 c startsStarts in 12 Hours 0-8
STARTSCompressor Ontime 0-500000.0 HOURS c hrs*Service Ontime
0-32767 HOURS S HRS*Compressor Motor kW 0-9999 kW CKW
NOTE: All values are variables available for read operation to a
CCN. Descriptions shown with (*) support write operations for BEST
programminglanguage, data transfer, and overriding.
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Table 2 LID Screens (cont)EXAMPLE 2 STATUS02 DISPLAY SCREEN
To access this display from the LID default screen:1. Press MENU
.2. Press STATUS .3. Scroll down to highlight STATUS02.4. Press
SELECT .
DESCRIPTION POINT TYPE UNITS REFERENCE POINT NAME(ALARM
HISTORY)INPUT OUTPUTHot Gas Bypass Relay X OFF/ON HGBR*Chilled
Water Pump X OFF/ON CHWPChilled Water Flow X NO/YES EVFL*Condenser
Water Pump X OFF/ON CDPCondenser Water Flow X NO/YES CDFLCompressor
Start Relay X OFF/ON CMPRCompressor Start Contact X OPEN/CLOSED 1CR
AUXCompressor Run Contact X OPEN/CLOSED RUN AUXStarter Fault
Contact X OPEN/CLOSED STR FLTPressure Trip Contact X OPEN/CLOSED
PRS TRIPSingle Cycle Dropout X NORMAL/ALARM V1 CYCLEOil Pump Relay
X OFF/ON OILROil Heater Relay X OFF/ON OILHMotor Cooling Relay X
OFF/ON MTRC*Tower Fan Relay X OFF/ON TFRCompr. Shunt Trip Relay X
OFF/ON TRIPRAlarm Relay X NORMAL/ALARM ALMSpare Prot Limit Input X
ALARM/NORMAL SPR PL
NOTE: All values are variables available for read operation to a
CCN. Descriptions shown with (*) support write operations from the
LID only.
EXAMPLE 3 STATUS03 DISPLAY SCREENTo access this display from the
LID default screen:1. Press MENU .2. Press STATUS .3. Scroll down
to highlight STATUS03.4. Press SELECT .
DESCRIPTION RANGE UNITS REFERENCE POINT NAME(ALARM
HISTORY)OPTIONS BOARD 1*Demand Limit 4-20 mA 4-20 mA DEM OPT*Temp
Reset 4-20 mA 4-20 mA RES OPT*Common CHWS Sensor 40-245 (40-118)
DEG F (DEG C) CHWS*Common CHWR Sensor 40-245 (40-118) DEG F (DEG C)
CHWR*Remote Reset Sensor 40-245 (40-118) DEG F (DEG C) R RESET*Temp
Sensor Spare 1 40-245 (40-118) DEG F (DEG C) SPARE1*Temp Sensor
Spare 2 40-245 (40-118) DEG F (DEG C) SPARE2*Temp Sensor Spare 3
40-245 (40-118) DEG F (DEG C) SPARE3OPTIONS BOARD 2*4-20 mA Spare 1
4-20 mA SPARE1 M*4-20 mA Spare 2 4-20 mA SPARE2 M*Temp Sensor Spare
4 40-245 (40-118) DEG F (DEG C) SPARE4*Temp Sensor Spare 5 40-245
(40-118) DEG F (DEG C) SPARE5*Temp Sensor Spare 6 40-245 (40-118)
DEG F (DEG C) SPARE6*Temp Sensor Spare 7 40-245 (40-118) DEG F (DEG
C) SPARE7*Temp Sensor Spare 8 40-245 (40-118) DEG F (DEG C)
SPARE8*Temp Sensor Spare 9 40-245 (40-118) DEG F (DEG C) SPARE9
NOTE: All values shall be variables available for read operation
to a CCN network. Descriptions shown with (*) support write
operations for BESTprogramming language, data transfer, and
overriding.
EXAMPLE 4 SETPOINT DISPLAY SCREENTo access this display from the
LID default screen:1. Press MENU .2. Press SETPOINT .
DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME
DEFAULT VALUEBase Demand Limit 40-100 % DLM 100LCW Setpoint 20-120
(6.7-48.9) DEG F (DEG C) lcw sp 50.0 (10.0)ECW Setpoint 20-120
(6.7-48.9) DEG F (DEG C) ecw sp 60.0 (15.6)ICE BUILD Setpoint 20-
60 (6.7-15.6) DEG F (DEG C) ice sp 40.0 ( 4.4)
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Table 2 LID Screens (cont)EXAMPLE 5 CONFIGURATION (CONFIG)
DISPLAY SCREEN
To access this display from the LID default screen:1. Press MENU
.2. Press SERVICE .3. Scroll down to highlight EQUIPMENT
CONFIGURATION.4. Press SELECT .5. Scroll down to highlight
CONFIG.6. Press SELECT .
DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME
DEFAULT VALUERESET TYPE 1Degrees Reset at 20 mA 30-30 (17-17) DEG F
(DEG C) deg 20ma 10D(6D)RESET TYPE 2Remote Temp (No Reset) 40-245
(40-118) DEG F (DEG C) res rt1 85 (29)Remote Temp (Full Reset)
40-245 (40-118) DEG F (DEG C) res rt2 65 (18)Degrees Reset 30-30
(17-17) DEG F (DEG C) res rt 10D(6D)RESET TYPE 3CHW Delta T (No
Reset) 0-15 (0-8) DEG F (DEG C) restd 1 10D(6D)CHW Delta T (Full
Reset) 0-15 (0-8) DEG F (DEG C) restd 2 0D(0D)Degrees Reset 30-30
(17-17) DEG F (DEG C) deg chw 5D(3D)Select/Enable Reset Type 0-3
res sel 0ECW CONTROL OPTION DISABLE/ENABLE ecw opt DISABLEDemand
Limit At 20 mA 40-100 % dem 20ma 4020 mA Demand Limit Option
DISABLE/ENABLE dem sel DISABLEAuto Restart Option DISABLE/ENABLE
astart DISABLERemote Contacts Option DISABLE/ENABLE r contact
DISABLETemp Pulldown Deg/Min 2-10 tmp ramp 3Load Pulldown %/Min
5-20 kw ramp 10Select Ramp Type: 0/1 ramp opt 1Temp = 0, Load =
1
Loadshed Group Number 0-99 ldsgrp 0Loadshed Demand Delta 0-60 %
ldsdelta 20Maximum Loadshed Time 0-120 MIN maxldstm 60CCN Occupancy
Config:Schedule Number 3-99 occpcxxe 3Broadcast Option
DISABLE/ENABLE occbrcst DISABLE
ICE BUILD Option DISABLE/ENABLE ibopt DISABLEICE BUILD
TERMINATION0 =Temp, 1 =Contacts, 2 =Both 0-2 ibterm 0
ICE BUILD Recycle Option DISABLE/ENABLE ibrecyc DISABLENOTE: D =
delta degrees.
EXAMPLE 6 LEAD/LAG CONFIGURATION DISPLAY SCREENTo access this
display from the LID default screen:1. Press MENU .2. Press SERVICE
.3. Scroll down to highlight EQUIPMENT CONFIGURATION.4. Press
SELECT .5. Scroll down to highlight Lead/Lag.6. Press SELECT .
LEAD/LAG CONFIGURATION SCREEN
DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME
DEFAULT VALUELEAD/LAG SELECTDISABLE =0, LEAD =1,LAG =2, STANDBY
=3
0-3 leadlag 0
Load Balance Option DISABLE/ENABLE loadbal DISABLECommon Sensor
Option DISABLE/ENABLE commsens DISABLELAG Percent Capacity 25-75 %
lag per 50LAG Address 1-236 lag add 92LAG START Timer 2-60 MIN
lagstart 10LAG STOP Timer 2-60 MIN lagstop 10PRESTART FAULT Timer
0-30 MIN preflt 5STANDBY Chiller Option DISABLE/ENABLE stndopt
DISABLESTANDBY Percent Capacity 25-75 % stnd per 50STANDBY Address
1-236 stnd add 93
NOTE: The Lead/Lag Configuration table is available on PSIO
Software Version 09 and higher.
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Table 2 LID Screens (cont)EXAMPLE 7 SERVICE1 DISPLAY SCREEN
To access this display from the LID default screen:1. Press MENU
.2. Press SERVICE .3. Scroll down to highlight EQUIPMENT SERVICE.4.
Press SELECT .5. Scroll down to highlight SERVICE1.6. Press SELECT
.
DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME
DEFAULT VALUEMotor Temp Override 150-200 (66-93) DEG F (DEG C) mt
over 200 (93)Cond Press Override 150-245 (1034-1689)[90-200
(620-1379)] PSI (kPa) cp over 195 (1345) [125 (862)]Refrig Override
Delta T 2-5 (1-3) DEG F (DEG C) ref over 3D (1.6D)Chilled Medium
Water/Brine medium WATERBrine Refrig Trippoint 8-40 (13.3-4) DEG F
(DEG C) br trip 33 (1)Compr Discharge Alert 125-200 (52-93) DEG F
(DEG C) cd alert 200 (93)Bearing Temp Alert 175-185 (79-85) DEG F
(DEG C) tb alert 175 (79)Water Flow Verify Time 0.5-5 MIN wflow t
5Oil Press Verify Time 15-300 SEC oilpr t 15Water/Brine Deadband
0.5-2.0 (0.3-1.1) DEG F (DEG C) cw db 1.0 (0.6)Recycle Restart
Delta T 2.0-10.0 (1.1-5.6) DEG F (DEG C) rcyc dt 5 (2.8)Recycle
Shutdown Delta T 0.5-4.0 (0.27-2.2) DDEG F (DDEG C) rcycs dt 1.0
(0.6)Surge Limit/HGBP Option 0/1 srg hgbp 0Select: Surge=0,
HGBP=1Surge/HGBP Delta T1 0.5-15 (0.3-8.3) DEG F (DEG C) hgb dt1
1.5 (0.8)Surge/HGBP Delta P1 50-170 (345-1172)[30-170 (207-1172)]
PSI (kPA) hgb dp1 75 (517) [50 (345)]Min. Load Points
(T1/P1)Surge/HGBP Delta T2 0.5-15 (0.3-8.3) DEG F (DEG C) hgb dt2
10 (5.6)Surge/HGBP Delta P2 50-170 (345-1172)[30-170 (207-1172)]
PSI (kPa) hgb dp2 170 (1172) [85 (586)]Full Load Points
(T2/P2)Surge/HGBP Deadband 1-3 (0.6-1.6) DEG F (DEG C) hgb dp 1
(0.6)Surge Delta Percent Amps 10-50 % surge a 25Surge Time Period
1-5 MIN surge t 2Demand Limit Source 0/1 dem src 0Select: Amps=0,
Load=1Amps Correction Factor 1-8 corfact 3Motor Rated Load Amps
1-9999 AMPS a fs 200Motor Rated Line Voltage 1-9999 VOLTS v fs
460Meter Rated Line kW 1-9999 kW kw fs 600Line Frequency 0/1 HZ
freq 0Select: 0=60 Hz, 1=50 HzCompr Starter Type REDUCE/FULL
starter REDUCECondenser Freeze Point 20-35 (28.9-1.7) DEG F (DEG C)
cdfreeze 34 (1)Soft Stop Amps Threshold 40-100 % softstop 100
NOTES:1. Condenser Freeze Point and Softstop Amps Threshold are
only selectable/readable on PSIO Software Versions 09 and higher.2.
Values in [ ] indicate HFC-134a values.3. D = delta degrees.
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Table 2 LID Screens (cont)EXAMPLE 8 SERVICE2 DISPLAY SCREEN
To access this display from the LID default screen:1. Press MENU
.2. Press SERVICE .3. Scroll down to highlight EQUIPMENT SERVICE.4.
Press SELECT .5. Scroll down to highlight SERVICE2.6. Press SELECT
.
DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME
DEFAULT VALUEOPTIONS BOARD 120 mA POWER CONFIGURATIONExternal = 0,
Internal = 1RESET 20 mA Power Source 0,1 res 20 ma 0DEMAND 20 mA
Power Source 0,1 dem 20 ma 0SPARE ALERT ENABLEDisable = 0, Low = 1,
High = 2Temp = Alert ThresholdCHWS Temp Enable 0-2 chws en 0CHWS
Temp Alert 40-245 (40-118) DEG F (DEG C) chws al 245 (118)CHWR Temp
Enable 0-2 chwr en 0CHWR Temp Alert 40-245 (40-118) DEG F (DEG C)
chwr al 245 (118)Reset Temp Enable 0-2 rres en 0Reset Temp Alert
40-245 (40-118) DEG F (DEG C) rres al 245 (118)Spare Temp 1 Enable
0-2 spr1 en 0Spare Temp 1 Alert 40-245 (40-118) DEG F (DEG C) spr1
al 245 (118)Spare Temp 2 Enable 0-2 spr2 en 0Spare Temp 2 Alert
40-245 (40-118) DEG F (DEG C) spr2 al 245 (118)Spare Temp 3 Enable
0-2 spr3 en 0Spare Temp 3 Alert 40-245 (40-118) DEG F (DEG C) spr3
al 245 (118)OPTIONS BOARD 220 mA POWER CONFIGURATIONExternal = 0,
Internal = 1SPARE 1 20 mA Power Source 0,1 sp1 20 ma 0SPARE 2 20 mA
Power Source 0,1 sp2 20 ma 0SPARE ALERT ENABLEDisable = 0, Low = 1,
High = 2Temp = Alert ThresholdSpare Temp 4 Enable 0-2 spr4 en
0Spare Temp 4 Alert 40-245 (40-118) DEG F (DEG C) spr4 al 245
(118)Spare Temp 5 Enable 0-2 spr5 en 0Spare Temp 5 Alert 40-245
(40-118) DEG F (DEG C) spr5 al 245 (118)Spare Temp 6 Enable 0-2
spr6 en 0Spare Temp 6 Alert 40-245 (40-118) DEG F (DEG C) spr6 al
245 (118)Spare Temp 7 Enable 0-2 spr7 en 0Spare Temp 7 Alert 40-245
(40-118) DEG F (DEG C) spr7 al 245 (118)Spare Temp 8 Enable 0-2
spr8 en 0Spare Temp 8 Alert 40-245 (0-118) DEG F (DEG C) spr8 al
245 (118)Spare Temp 9 Enable 0-2 spr9 en 0Spare Temp 9 Alert 40-245
(40-118) DEG F (DEG C) spr9 al 245 (118)
NOTE: This screen provides the means to generate alert messages
based on exceeding the Temp Alert threshold for each point listed.
If theEnable is set to 1, a value above the Temp Alert threshold
shall generate an alert message. If the Enable is set to 2, a value
below the TempAlert threshold shall generate an alert message. If
the Enable is set to 0, alert generation is disabled.
EXAMPLE 9 SERVICE3 DISPLAY SCREENTo access this display from the
LID default screen:1. Press MENU .2. Press SERVICE .3. Scroll down
to highlight EQUIPMENT SERVICE.4. Press SELECT .5. Scroll down to
highlight SERVICE3.
DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME
DEFAULT VALUEProportional Inc Band 2-10 gv inc 6.5Proportional Dec
Band 2-10 gv de 6.0Proportional ECW Gain 1-3 gv ecw 2.0Guide Vane
Travel Limit 30-100 % gv lim 50
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Table 2 LID Screens (cont)EXAMPLE 10 MAINTENANCE (MAINT01)
DISPLAY SCREEN
To access this display from the LID default screen:1. Press MENU
.2. Press SERVICE .3. Scroll down to highlight ALGORITHM STATUS.4.
Press SELECT .5. Scroll down to highlight MAINT01.
DESCRIPTION RANGE/STATUS UNITS REFERENCE POINT NAMECAPACITY
CONTROLControl Point 10-120 (12.2-48.9) DEG F (DEG C) ctrlptLeaving
Chilled Water 40-245 (40-118) DEG F (DEG C) LCWEntering Chilled
Water 40-245 (40-118) DEG F (DEG C) ECWControl Point Error 99-99
(55-55) DEG F (DEG C) cperrECW Delta T 99-99 (55-55) DEG F (DEG C)
ecwdtECW Reset 99-99 (55-55) DEG F (DEG C) ecwresLCW Reset 99-99
(55-55) DEG F (DEG C) lcwresTotal Error + Resets 99-99 (55-55) DEG
F (DEG C) errorGuide Vane Delta 2-2 % gvdTarget Guide Vane Pos
0-100 % GV TRGActual Guide Vane Pos 0-100 % GV ACTProportional Inc
Band 2-10 gv incProportional Dec Band 2-10 gv decProportional ECW
Gain 1-3 gv ecwWater/Brine Deadband 0.5-2 (0.3-1.1) DEG F (DEG C)
cwdb
NOTE: Overriding is not supported on this maintenance screen.
Active overrides show the associated point in alert (*). Only
values with capital letterreference point names are variables
available for read operation.
EXAMPLE 11 MAINTENANCE (MAINT02) DISPLAY SCREENTo access this
display from the LID default screen:1. Press MENU .2. Press SERVICE
.3. Scroll down to highlight CONTROL ALGORITHM STATUS.4. Press
SELECT .5. Scroll down to highlight MAINT02.6. Press SELECT .
DESCRIPTION RANGE/STATUS UNITS REFERENCE POINT
NAMEOVERRIDE/ALERT STATUSMOTOR WINDING TEMP 40-245 (40-118) DEG F
(DEG C) MTRWOverride Threshold 150-200 (66-93) DEG F (DEG C) mt
overCONDENSER PRESSURE 6.7-420 (42-2896) PSI (kPa) CRPOverride
Threshold 90-245 (621-1689) PSI (kPa) cp overEVAPORATOR REFRIG TEMP
40-245 (40-118) DEG F (DEG C) ERTOverride Threshold 2-45 (1-7.2)
DEG F (DEG C) rt overDISCHARGE TEMPERATURE 40-245 (40-118) DEG F
(DEG C) CMPDAlert Threshold 125-200 (52-93) DEG F (DEG C) cd
alertBEARING TEMPERATURE 40-245 (40-118) DEG F (DEG C) MTRBAlert
Threshold 175-185 (79-85) DEG F (DEG C) tb alert
NOTE: Overriding is not supported on this maintenance screen.
Active overrides show the associated point in alert (*). Only
values with capital letterreference point names are variables
available for read operation.
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Table 2 LID Screens (cont)EXAMPLE 12 MAINTENANCE (MAINT03)
DISPLAY SCREEN
To access this display from the LID default screen:1. Press MENU
.2. Press SERVICE .3. Scroll down to highlight CONTROL ALGORITHM
STATUS.4. Press SELECT .5. Scroll down to highlight MAINT03.6.
Press SELECT .
DESCRIPTION RANGE/STATUS UNITS REFERENCE POINT NAMESURGE/HGBP
ACTIVE ? NO/YESActive Delta P 0-200 (0-1379) PSI (kPa) dp aActive
Delta T 0-200 (0-111) DEG F (DEG C) dt aCalculated Delta T 0-200
(0-111) DEG F (DEG C) dt cSurge Protection Counts 0-12 spc
NOTE: Override is not supported on this maintenance screen. Only
values with capital letter reference point names are variables
available for readoperation.
EXAMPLE 13 MAINTENANCE (MAINT04 DISPLAY SCREENTo access this
display from the LID default screen:1. Press MENU .2. Press SERVICE
.3. Scroll down to highlight CONTROL ALGORITHM STATUS.4. Press
SELECT .5. Scroll down to highlight MAINT04.6. Press SELECT .
DESCRIPTION RANGE/STATUS UNITS REFERENCE POINT NAMELEAD/LAG:
Configuration DISABLE,LEAD,LAG,STANDBY, INVALID leadlag
Current Mode DISABLE,LEAD,LAG,STANDBY, CONFIG llmodeLoad Balance
Option DISABLE/ENABLE loadbalLAG Start Time 0-60 MIN lagstartLAG
Stop Time 0-60 MIN lagstopPrestart Fault Time 0-30 MIN
prefltPulldown: Delta T/Min 2-10 F/min (1.1-5.5 C/min) D DEG F/min
pull dt
Satisfied? No/Yes (D DEG C/min) pull satLEAD CHILLER in Control
No/Yes leadctrlLAG CHILLER: Mode Reset,Off,Local,CCN lagmode
Run Status
Timeout,Recycle,Startup,Ramping,RunningDemand,Override,Shutdown,Abnormal,Pumpdown
lagstat
Start/Stop Stop,Start,Retain lag s sRecovery Start Request
No/Yes lag recSTANDBY CHILLER: Mode Reset,Off,Local,CCN stdmode
Run Status
Timeout,Recycle,Startup,Ramping,RunningDemand,Override,Shutdown,Abnormal,Pumpdown
stdstat
Start/Stop Stop,Start,Retain std s sRecovery Start Request
No/Yes std rec
NOTES:1. Only values with capital letter reference point names
are variables available for read operation. Forcing is not
supported on this maintenance
screen.2. The MAINT04 screen is available on PSIO Software
Version 09 and higher.3. D = delta degrees.
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PIC System FunctionsNOTE: Throughout this manual, words printed
in capital let-ters and italics represent values that may be viewed
on theLID. See Table 2 for examples of LID screens. Point namesare
listed in the Description column. An overview of LIDoperation and
menus is given in Fig. 13-19.CAPACITY CONTROL The PIC controls the
chillercapacity by modulating the inlet guide vanes in response
tochilled water temperature changes away from the CON-TROL POINT.
The CONTROL POINT may be changed bya CCN network device, or is
determined by the PIC addingany active chilled water reset to the
ECW (Entering ChilledWater) SET POINT or LCW SET POINT. The PIC
uses thePROPORTIONAL INC (Increase) BAND, PROPORTIONALDEC
(Decrease) BAND,and thePROPORTIONALECWGAINto determine how fast or
slow to respond.CONTROL POINTmay be viewed/overridden on the Status
table, Status01selection.ENTERING CHILLED WATER CONTROL If this
op-tion is enabled, the PIC uses ENTERING CHILLED WATERtemperature
to modulate the vanes instead of LEAV-ING CHILLEDWATER temperature.
ENTERING CHILLEDWATER control option may be viewed/modified on the
Equip-ment Configuration table, Config table.DEADBAND This is the
tolerance on the chilled water/brine temperature CONTROL POINT. If
the water temper-ature goes outside of theDEADBAND, the PIC opens
or closesthe guide vanes in response until it is within tolerance.
ThePIC may be configured with a 0.5 to 2 F (0.3 to 1.1 C)
dead-band.DEADBANDmay be viewed or modified on the Equip-ment
Service1 table.For example, a 1 F (0.6 C) deadband setting
controls
the water temperature within 0.5 F (0.3 C) of the con-trol
point. This may cause frequent guide vane movement ifthe chilled
water load fluctuates frequently. A value of1 F (0.6 C) is the
default setting.PROPORTIONALBANDSANDGAINProportional bandis the
rate at which the guide vane position is corrected inproportion to
how far the chilled water/brine temperature isfrom the control
point. Proportional gain determines howquickly the guide vanes
react to how quickly the tempera-ture is moving from CONTROL
POINT.The proportional band can be viewed/modified on the LID.There
are two response modes, one for temperature re-sponse above the
control point, the other for response belowthe control point.The
first type is called PROPORTIONAL INC BAND, and
it can slow or quicken vane response to chilled water/brine
temperature above DEADBAND. It can be adjustedfrom a setting of 2
to 10; the default setting is 6.5. PRO-PORTIONAL DEC BAND can slow
or quicken vane re-sponse to chilledwater temperature belowdeadband
plus controlpoint. It can be adjusted on the LID from a setting of
2 to 10,and the default setting is 6.0. Increasing either of these
set-tings will cause the vanes to respond slower than at a
lowersetting.The PROPORTIONALECWGAIN can be adjusted at the
LIDdisplay from a setting of 1.0 to 3.0, with a default setting
of2.0. Increase this setting to increase guide vane response toa
change in entering chilled water temperature. The propor-tional
bands and gain may be viewed/modified on the Equip-ment Service3
table.
DEMAND LIMITING The PIC will respond to theACTIVE DEMAND LIMIT
set point by limiting the open-ing of the guide vanes. It will
compare the set pointto either COMPRESSOR MOTOR LOAD or COMPRES-SOR
MOTOR CURRENT (percentage), depending on howthe control is
configured for the DEMAND LIMIT SOURCEwhich is accessed on the
SERVICE1 table. The default set-ting is current limiting.
CHILLER TIMERSThe PIC maintains 2 runtime clocks,known as
COMPRESSOR ONTIME and SERVICE ON-TIME. COMPRESSOR ONTIME indicates
the total life-time compressor run hours. This timer can register
upto 500,000 hours before the clock turns back to zero. TheSERVICE
ONTIME is a resettable timer that can be used toindicate the hours
since the last service visit or any otherreason. The time can be
changed through the LID towhatever value is desired. This timer can
register up to32,767 hours before it rolls over to zero.The chiller
also maintains a start-to-start timer and a stop-
to-start timer. These timers limit how soon the chiller can
bestarted. See the Start-Up/Shutdown/Recycle Sequence sec-tion,
page 39, for operational information.
OCCUPANCYSCHEDULEThis schedule determineswhenthe chiller is
either occupied or unoccupied.Each schedule consists of from one to
8 occupied/unoccupied
time periods, set by the operator. These time periods can
beenabled to be in effect, or not in effect, on each day of theweek
and for holidays. The day begins with 0000 hours andends with 2400
hours. The chiller is in OCCUPIED modeunless an unoccupied time
period is in effect.The chiller will shut down when the schedule
goes to UN-
OCCUPIED. These schedules can be set up to follow thebuilding
schedule or to be 100% OCCUPIED if the operatorwishes. The
schedules also can be bypassed by forcing theStart/Stop command on
the PIC Status screen to start. Theschedules also can be overridden
to keep the unit in an OC-CUPIED mode for up to 4 hours, on a
one-time basis.Figure 18 shows a schedule for a typical office
building
time schedule, with a 3-hour, off-peak cool down periodfrom
midnight to 3 a.m., following a weekend shutdown.Example: Holiday
periods are unoccupied 24 hours per day.The building operates
Monday through Friday, 7:00 a.m. to6:00 p.m., with a Saturday
schedule of 6:00 a.m. to1:00 p.m., and includes the Monday midnight
to 3:00 a.m.weekend cool-down schedule.NOTE: This schedule is for
illustration only, and is not in-tended to be a recommended
schedule for chiller operation.PSIO Software Version 08 and Lower
Whenever the chilleris in the LOCAL mode, the chiller will start
when theOccupancy Schedule 01 indicates OCCUPIED. When in theCCN
mode, Occupancy Schedule 02 is used.PSIO Software Version 09 and
Higher The Local TimeSchedule is still the Occupancy Schedule 01.
The Ice BuildTime Schedule is Schedule 02 and the CCN Default
TimeSchedule is Schedule 03. The CCN schedule number is de-fined on
the Config table in the Equipment Configurationtable on page 23.
The schedule number can change to anyvalue from 03 to 99. If this
schedule number is changed onthe Config table, the operator must
use the Attach to Net-work Device table to upload the new number
into the Sched-ule screen. See Fig. 17.
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Safety Controls The PIC monitors all safety controlinputs, and
if required, shuts down the chiller or limits theguide vanes to
protect the chiller from possible damage fromany of the following
conditions: high bearing temperature high motor winding temperature
high discharge temperature low oil pressure low cooler refrigerant
temperature/pressure condenser high pressure or low pressure
inadequate water/brine cooler and condenser flow high, low, or loss
of voltage excessive motor acceleration time excessive starter
transition time lack of motor current signal excessive motor amps
excessive compressor surge temperature and transducer faults
Starter faults or optional protective devices within the
startercan shut down the chiller. These devices are dependent
onwhat has been purchased as options.
If compressor motor overload occurs, check the motorfor grounded
or open phases before attempting arestart.
If the controller initiates a safety shutdown, it displaysthe
fault on the LID display with a primary and a secondarymessage, and
energizes an alarm relay in the starter and blinksthe alarm light
on the control center. The alarm is stored inmemory and can be
viewed in the PIC alarm table along witha message for
troubleshooting.
To give a better warning as to the operating condition ofthe
chiller, the operator also can define alert limits on vari-ous
monitored inputs. Safety contact and alert limits aredefined in
Table 3. Alarm and alert messages are listed in theTroubleshooting
Guide section, page 66.SHUNTTRIPThe shunt trip function of the PIC
is a safetytrip. The shunt trip is wired from an output on the SMM
toa shunt trip-equipped motor circuit breaker. If the PIC triesto
shut down the compressor through normal shutdown pro-cedure but is
unsuccessful for 30 seconds, the shunt trip out-put is energized
and causes the circuit breaker to trip off. Ifground fault
protection has been applied to the starter, theground fault trip
will also energize the shunt trip to trip thecircuit breaker.
Default Screen Freeze Whenever an alarmoccurs, the LID default
screen will freeze displaying thecondition of the chiller at the
time of alarm. Knowledge ofthe operating state of the chiller at
the time an alarm occursis useful when troubleshooting. Current
chiller informationcan be viewed on the Status tables. Once all
existing alarmsare cleared (by pressing the RESET softkey), the
defaultLID will return to normal operation.Motor Cooling Control
Motor temperature isreduced by refrigerant entering the motor shell
and evap-orating. The refrigerant is regulated by the motor
coolingrelay. This relay will energize when the compressor is
run-ning and motor temperature is above 125 F (51.7 C). Therelay
will close when motor temperature is below 100 F(37.8 C). Note that
there is always a minimum flow ofrefrigerant when the compressor is
operating for motor cool-ing; the relay only controls additional
refrigerant to themotor.
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Table 3 Protective Safety Limits and Control SettingsMONITORED
PARAMETER LIMIT APPLICABLE COMMENTS
TEMPERATURE SENSORSOUT OF RANGE 40 to 245 F (40 to 118.3 C) Must
be outside range for 2 seconds
PRESSURE TRANSDUCERSOUT OF RANGE 0.08 to 0.98 Voltage Ratio
Must be outside range for 2 seconds.Ratio = Input Voltage
VoltageReference
COMPRESSOR DISCHARGETEMPERATURE .220 F (104.4 C) Preset, alert
setting configurableMOTOR WINDING TEMPERATURE .220 F (104.4 C)
Preset, alert setting configurableBEARING TEMPERATURE .185 F (85 C)
Preset, alert setting configurable
EVAPORATOR REFRIGERANTTEMPERATURE
,33 F (for water chilling) (0.6 C) Preset, configure chilled
medium forwater (Service1 table),Brine Refrigerant Trippoint (set
point adjustablefrom 0 to 40 F [18 to 4 C] for brine chilling)
Configure chilled medium for brine(Service1 table). Adjust brine
refrigeranttrippoint for proper cutout
TRANSDUCER VOLTAGE ,4.5 vdc . 5.5 vdc PresetCONDENSER PRESSURE
SWITCH .263 7 psig (1813 48 kPa),reset at 180 10 (1241 69 kPa)
Preset
CONTROL .260 psig (1793 kPa) for HCFC-22;215 psig (1482 kPa) for
HFC-134a PresetOIL PRESSURE SWITCH Cutout ,11 psid (76 kPad) 1.5
psid (10.3 kPad)
Cut-in .16.5 psid (114 kPad) 4 psid (27.5 kPad) Preset, no
calibration needed
CONTROL Cutout ,15 psid (103 kPad)Alert ,18 psi